Methods of manufacturing coils and apparatus for same

ABSTRACT

A spring assembly having a coil containing a core and methods and apparatus for manufacturing same are disclosed. The coil includes a core between reduced portions of the coil. One device for manufacturing the coil includes a coiling machine having an insert device operable with a coiler. The coiler is programmed to form coils of appropriate diameter along the length of the coil, including a diameter sufficiently large to contain the core and two diameters sufficiently small to retain the core in the coil. The insert device transfers the core to the coil after the first small diameter is formed and before the second small diameter is formed. The coil with the core contained between the two small diameters is thereby manufactured in a unified automated process.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a Continuation of U.S. patent applicationSer. No. 09/798,645, filed Mar. 1, 2001, which is a Continuation of U.S.patent application Ser. No. 09/378,121, filed Aug. 19, 1999.Accordingly, this application claims the benefit of an earlier filingdate under 35 U.S.C. §120.

BACKGROUND OF THE INVENTION

[0002] The disclosure of U.S. pat. app. Ser. Nos. 09/378,121 and09/798,645 are incorporated herein by reference.

[0003] The present invention relates to coiling machines, although otheruses will be apparent from the teachings disclosed herein. Inparticular, the present invention relates to coiled spring assembliesproduced in a unified process. A specific embodiment of the coiledspring assemblies includes coiled ferrite spring assemblies which are ofparticular use in the automotive industry for reduction ofelectromagnetic interference (EMI) during ignition system firing.

[0004] Spring coiling machines are well known in the art. Spring coilingmachines and methods are discussed in U.S. Pat. No. 5,036,690, entitled“Flexible Pipe End Crimping Apparatus,” issued Aug. 6, 1991; U.S. Pat.No. 5,452,598, entitled “Automatic Spring Formation Apparatus,” issuedSep. 26, 1995; and U.S. Pat. No. 5,791,184, entitled “Spring-MakingMachine,” issued Aug. 11, 1998. U.S. Pat. Nos. 5,036,690; 5,452,598; and5,791,184 are incorporated herein, in their entirety, by reference. Itis also known in the art to provide inserts in springs.

[0005] It has, however, been difficult to manufacture spring assemblieswith plugs in a single continuous or unified process. Generally, theinsert might be maintained in place by crimping the coils around theinsert or inserting wire or flat stock about the ends of the coil tohold down the insert within the coil. These and other prior art methodsfor producing coiled plugs usually require inserting the plug into thecoil after the coil is produced as a finished product. For example, thespring is manufactured, then in a separate process the cylinder isinserted into the spring (typically “by hand”). And then, in anotherseparate process, the cylinder is secured in the spring by one of theaforementioned methods. These prior art methods involve multipleseparate steps, often done by hand, and as a result have reliability andefficiency problems associated with them.

[0006] The present invention overcomes these problems and providesadvantages heretofore unattainable.

SUMMARY OF THE INVENTION

[0007] The present invention relates to coiling machines and springsgenerally. It more particularly relates to machines and methods formanufacturing spring assemblies having a core inserted into the coil.The core may be one or more elements and the assemblies may have avariety of configurations. Accordingly, one object of the presentinvention is to provide a new and improved spring coiling machine.

[0008] Another object is to provide a consistent and reliable method ofmanufacture coiled spring assemblies at a reduced cost.

[0009] Another object of the present invention is to provide methods ofmanufacturing coiled spring assemblies in a unified manufacturingprocess.

[0010] Yet another object is to provide an improved spring assembly.

[0011] Another object of the present invention is to provide acontinuous coiled spring assembly manufacturing process and apparatusfor same.

[0012] Accordingly, one embodiment of the present invention is a coilingmachine. The coiling machine includes a coiler adapted to form a coilhaving a first diameter and a second diameter. The second diameter ispreferably smaller than the first diameter. Although not required forall applications, multiple diameters are preferred, includingsubstantially equal (or uniform) multiple diameters. An insert device ispositioned to insert a core into the coil, wherein the core has a corediameter between the first diameter and the second diameter, e.g. thecore is smaller than the first diameter and larger than the seconddiameter. Thus, the core may be contained in one diameter (the firstdiameter) of the coil by another smaller diameter (the second diameter).Core as used herein (also referred to as a “plug”) is intended to bebroadly construed (as is “plug”) to include any material and shape whichmay be inserted into the coil. Materials, including plastic andaluminum, are selected to meet specific application requirements, toreduce vibration or to achieve artificial solid height. Otherapplications will be apparent to those with skill in the art from theteachings disclosed herein.

[0013] Another coiling machine according to the present inventionincludes a coiler adapted to form a coil having a first diameter and aplurality of reduced portions. The plurality of reduced portions includea first reduced portion and a second reduced portion wherein the secondreduced portion is located a spaced distance from the first reducedportion. An insert device is positioned to insert a core in the coilbetween the first and second reduced portions. The first diameter may bebetween the reduced portions or to either side of them. The insertdevice includes transfer structure to transfer the core from a firstposition to a second position. The second position is adjacent to thecoil for some applications, though in general it need not be.

[0014] Accordingly, the present invention envisions a coil comprising alength, a major diameter (generally as part of the coil body) definingan interior, and a first reduced portion. The core is inserted into theinterior and maintained in the interior by the reduced portion.Alternative methods eliminating the need for reduced portions are alsoprovided. Use of a deformable core is one such method.

[0015] The present invention encompasses numerous methods ofmanufacturing coils, including spring assemblies having cores. Onemethod includes the steps of forming a first diameter section andforming a first reduced portion. A core is inserted into the coil so asto be between the first reduced portion and a subsequently formedreduced portion.

[0016] One method of the present invention for manufacturing a springassembly includes providing a continuous stream of wire to a coiler andproviding a continuous stream of cores to an insert device positioned inthe coiler. The wire is coiled into a first reduced portion and into acoil body (or coil core) having a diameter sufficiently large to containthe core. The core is inserted through (or into) the coil body up to thefirst reduced portion or there about.

[0017] The coil body is generally located mid-length of the coil and thecoils are generally spaced closer together (along the length of thecoil) in the coil body. Variations will be apparent to those with skillin the art.

[0018] Other objects and advantages of the present invention will beapparent from the following detailed discussion of exemplary embodimentswith reference to the attached drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 shows an elevated side view of a coiling machine accordingto the present invention.

[0020]FIG. 2 shows an elevated front view of the coiling machinedepicted in FIG. 1.

[0021]FIG. 3 shows a plan view of the coiling machine shown in FIG. 1.

[0022]FIG. 4 shows a partial top view of transfer structure fortransferring a core to a coil. FIG. 4 is rotated 180° from the viewshown in FIG. 3.

[0023]FIG. 5 shows a perspective view of the transfer structure with thefeed tube removed for clarity. The transfer block is shown at a firstposition.

[0024]FIG. 6 is a perspective view of the transfer structure with thetransfer block in a second position adjacent to the coil.

[0025]FIG. 7 is an elevated side view of a feed structure. Cores areshown staged on a track to be fed on demand by the feed mechanismthrough the feed tube to the transfer block.

[0026]FIG. 8 shows a partial view of coiling points and a moveable arborcutting block combination for cutting the wire.

[0027]FIG. 9 shows an elevated side view of a coil having a plurality ofdiameters.

[0028]FIG. 9a shows a section view of the spring assembly of FIG. 9 cutthrough section line 9 a-9 a.

[0029]FIG. 10 shows an end view of the coil shown in FIG. 9. A firstlarger diameter and a second smaller diameter are shown in the end view.

[0030]FIG. 11 shows an elevated side view of a core sized to fit withinthe coil shown in FIG. 9.

[0031]FIG. 12 shows an end view of the core shown in FIG. 11. The corehas a diameter sufficiently small to fit within the coil shown in FIG.9.

[0032]FIG. 13 shows a front close-up view of the coiling points. Thewire is being continuously fed to the coiling points.

[0033]FIG. 14 shows the coiling points of FIGS. 13 in a withdrawnposition.

[0034]FIG. 15 shows a right side view of the coiling machine shown inFIG. 1.

[0035]FIG. 16 shows a close up view of the interior of the coilingmachine shown in FIG. 15. The transfer block is shown in a firstposition.

[0036]FIG. 17 is a top view looking into the interior of the coilingmachine 12.

[0037]FIG. 18 is similar to the view shown in FIG. 17; the cam shaft,however, is removed for clarity.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0038] The present invention is discussed in relation to a coiler, andin particular, a wire coiler for forming a spring assembly having a core(or plug); other uses will be apparent from the teachings disclosedherein. The present invention will be best understood from the followingdetailed description of exemplary embodiments with reference to theattached drawings, wherein like reference numerals and characters referto like parts, and by reference to the following claims.

[0039]FIG. 1 depicts an elevated side view of a coiling machine 10according to the present invention. The coiling machine 10 includes acoiler 12 adapted to form a coil 14 (see FIGS. 9 and 10), having a firstdiameter 16 and a second diameter 18, wherein the second diameter 18 issmaller than the first diameter 16. Referring to FIG. 9, the coil 14comprises a length 20, a major diameter 22 defining an interior 24(shown well in FIG. 10) and a first reduced portion 26. In theembodiment shown in FIGS. 9 and 10 the first reduced portion 26 is alsoreferred to as the second diameter 18. The coil 14 shown in FIG. 9includes a first diameter section 28, a first reduced portion 26 and asecond diameter section 30; the second diameter section 30 is alsoreferred to herein as a coil body diameter section (or simply coil bodywhere appropriate). A third diameter section 32 is separated from thesecond diameter section 30 by a second reduced portion 34. Oneembodiment of the present invention is adapted from a ITAYA PC-15available from A.I. Technology of Southfield, Mich., ITAYA's U.S.A.Distributor. The ITAYA PC-15 includes the ability to manufacture springsof different diameters.

[0040] In one embodiment, the coil body diameter 30 has a maximumoutside diameter of 8.43 mm; the interior diameter, preferably at eachend of the coil 14, is 6.45 mm. A core 38 having a 6.35 mm diameter 40is inserted into the coil body diameter 30 to form a spring assembly 31.To maintain the plug 38 in the coil body diameter 30, the reduced coilportions 26 and 34 are reduced to less than 6.35 mm diameter. In thisembodiment the coil 14 has a length 20 of 106 mm and the plug 38 has alength 39 of 31.75 mm.

[0041] Though the invention is described in terms of “diameters,” theinvention is not limited to cylinders having circular cross sections.Diameter, and similar terms, are used herein for simplicity and shouldbe construed broadly. For instance, diameter should include meaningssuch as elongated, elliptical, flattened, stretched, and the like.Further, the track, tube and insert device (discussed in more detailbelow) can be configured to coordinate with non-circular cross-sectionsprings.

[0042] Coilers, similar to the coiler 12 shown in FIG. 1, are well knownin the art and are programmable to form coils having a plurality ofdiameters such as shown in FIG. 9. The coiler is shown in FIG. 1,however, includes the improvements taught herein, such as insertdevices, cams and pneumatic controls (air blasts and the like). Thecoiling machine 10 shown in FIG. 1 includes one such insert device 36(shown in FIGS. 4, 5 and 6). The insert device 36 is positioned toinsert a plug 38 into the coil 14. Referring to FIGS. 10 and 12, theplug 38 has a plug diameter 40 between the first diameter 16 and thesecond diameter 18, i.e. the measurement of plug diameter 40 is betweenthe measurements of the first and second diameters 16 and 18. The plug38 is insertable into a coil 14 having a first diameter 16 which issufficiently large to contain the plug 38; the second diameter 18 issufficiently small to maintain the plug 38 in the coil 14. The terms“plug” and “core” are used interchangeably, except where distinction ismade, and are to be construed to generally include all insertableelements.

[0043]FIG. 1 shows the feed structure 42 operably connected to theinsert device 36 (shown in the coiler 12 cut out in FIG. 3.). FIGS. 2and 3 are front and top views respectively of the coiling machine 10.The directions and orientations are provided for convenience only andnot as limitations. Other feed structure embodiments within the scope ofthe invention will be apparent to those of skill.

[0044]FIG. 4 shows a top view of an embodiment of the insert device 36,including transfer structure 44. The transfer structure 44 includes atransfer block 46 for transferring the plug 38 (not shown in FIG. 4)from a first position 48 to a second position 50 adjacent to the coil14. The transfer structure 44 also includes a transfer element 52positioned to transfer the plug 38 from the transfer block 46 to thecoil 14. In the embodiment shown in FIG. 4, the transfer element 52includes an air cylinder 54 having a plunger 56. In one preferredembodiment the plunger 56 is positioned to be insertable into the coil14. This is useful with semi-deformable cores. The plunger 56 movementis preferably coordinated with the movement of the coiling points 76 andthe arm 79 shown in FIG. 8.

[0045] Referring to FIGS. 1 and 4, the feed structure 42 comprises aconduit 58 having a first end 60 adjacent to the first position 48. FIG.7 shows an embodiment of the conduit 58 including a feed tube 62connected to a track 64 by a feed mechanism 66. The feed mechanism 66may include a sensor 67 (or sensors) in (or on, and other operableorientations relative to) the track 64. The sensor for track 64 tellsthe vibratory feed bowl 72 when to start and stop. This guarantees coresare available for insertion. The sensor also may be used for othertiming, detection, and coordination functions. Any one of a number ofvibratory bowls available from multiple manufacturers will be suitable.

[0046]FIGS. 5 and 6 show perspective views of the transfer mechanism 44.In FIG. 5, feed tube 62 has been removed to more clearly show thetransfer block 46. The transfer block 46 includes a channel 68 forreceiving the plug 38. In FIG. 5 the transfer block channel 68 is at thefirst position 48 for receiving the plug 38. In the embodiment shown inFIGS. 5 and 6 the transfer block 46 is laterally moveable. The transferblock 46 need not be air actuated, furthermore, other embodiments do notrequire the transfer block 46 at all. Computer controlled switches maybe used to achieve precise timing control. FIG. 6 shows the transferblock 46 moved to the second position 50. The feed tube 62 is positionedto deliver the plug 38 to the first position 48. The air cylinder 54 isshown transferring the plug 38 from the transfer of block 46 to the coil14.

[0047] The feed structure 42 shown in FIG. 7 includes a vibratory feedbowl 72. More generally, the vibratory feed bowl 72 may be a coresource, or insert source, 72. The conduit 58 includes a second end 74positioned to receive a plug 38 from the vibratory feed bowl 72. In onepreferred embodiment the vibratory feed bowl 72 is used to singulate thecores 38, i.e. separate out a single core from a plurality of cores. Forsome applications, singulating includes aligning the cores end to end.The track 64 or the feed mechanism 66 may also be used to singulate thecores. In the embodiment shown in FIG. 7 the feed bowl 72 is positionedhigher than the conduit first end 60. This positioning is one method ofachieving gravity assisted feeding. The feed bowl 72 and the track 64maybe used to orient the plug, or plugs, 38 and stage the plugs 38 fordelivery to the transfer block 46. In one preferred embodiment the plugs38 are staged at the feed mechanism 66 for delivery on demand to thetransfer block 46 or the insert device 36 generally.

[0048]FIGS. 15 through 18 show close-ups of the interior of the coiler12. FIG. 15 is a right side view of the coiler 12 showing the interior.FIG.16 is an enlarged view of FIG. 15, the transfer block 46 is shownadjacent to the conduit first end 60. Transfer element 52 is shownadjacent to and generally parallel with the feed tube 62. After thetransfer block moves the core 38 from the first position 48 to thesecond position 50, the air cylinder 54 would then transfer the core 38through hole 81. FIGS. 17 and 18 are top views looking into the coiler12; FIG. 18 shows hole 81 from inside the machine.

[0049] In one method of the invention, the coiler 12 produces the firstreduced portion 26 of the coil 14 (spring 14) and begins, and preferablycompletes, the coil body diameter 30 while the plug 38 is oriented,staged and transferred to the transfer block 46. Variations of thisapproach will be apparent from the teachings herein. The coiler 12produces a second reduced portion 34 located a spaced distance 35 fromthe first reduced portion 26 wherein the spaced distance 35 issufficiently long to contain the plug 38 in the coil 14. The spaceddistance 35 may be sized to contain a multiplicity of plugs. The majordiameter 22 shown in FIG. 9 is substantially uniform, i.e. the diameters28, 30 and 32 are substantially equal. FIG. 9a shows a cross-section ofthe spring assembly 31 shown in FIG. 9 through section lines 9 a-9 a.The core 38 is shown positioned in the coil 14.

[0050] Another method of manufacturing the spring assembly 31 includesthe steps of forming a first diameter section 28 and forming a firstreduced portion 26. A core 38 is inserted into a coil 14. Generally, thefirst reduced portion 26 is formed before the core 38 is inserted intothe coil 14. In a preferred embodiment a coil body 30 is formed, thenthe core 38 is inserted into the coil 14; a second reduced portion 34 isthen formed after the core 38 is inserted into the coil 14. Thismaintains the core 38 in position between the first reduced portion 26and the second reduced portion 34. Coiling points 76, shown in FIG. 8,preferably form a second diameter section 30 after forming the firstreduced portion 26. In one method the first diameter section 28 has beenformed before the first reduced portion 26 is formed and before the core38 is inserted into the second diameter section 30. Thus, describing thecoil length-wise, the coil has a first diameter, then a reduced portion,then a second diameter. The plug is then inserted into the seconddiameter behind the reduced portion. Another diameter is formed behindthe reduced portion.

[0051] Coiling may be stopped (but need not be) prior to inserting thecore 38. The stopping of coiling may result in a more consistent finalpart. The coiling points 76 are withdrawn, or backed off when coiling isstopped, as shown in FIG. 14 which should be compared with FIG. 13 inwhich the points 76 are in coiling position. Withdrawing the coilingpoints facilitates insertion of the core 38 (and plunger 56) in the coil14. Ann 79 is positioned to align hole 81 with the coil 14. Wire 82 iscontinuously fed from a wire payout (not shown) to the coiling points76. The coiling points 76 are generally moved in and out according topreprogrammed computer instructions.

[0052] An arbor 78 is moved up and down by a cam 83, shown best in FIGS.15 and 17. The arbor is up (see FIG. 13) except when cutting, and thenthe cutting block 80 comes down across the arbor to cut the wire atpredetermined lengths or intervals to produce spring assemblies ofpredetermined lengths 20. In a preferred embodiment the arbor 78 is onthe same block (arm) 79 through which the core 38 is inserted. The core38 is inserted into coil 14 through hole 81. Generally after the plug 38has been inserted into the coil 14, coiling will resume to eithercomplete the core body 30 or to form a reduced section 34 whichmaintains the core 38 in the coil 14. It may be preferable to back theplunger 56 out of the coil 14 prior to resuming coiling. This allows thecoiling points to reduce subsequent coil portions for core retention.

[0053] Those who have skill in the art will understand that the coiler12 may perform standard coiling processes and variations thereof inaddition to the inventive features taught herein. Accordingly, the core38 may be positioned when the coiler has reached a predetermined pointin the coiling process, or cycle. The track 64, or the feed mechanism66, or other devices known to those with skill in the art, may be usedto stage the core 38 until that point in the cycle.

[0054] One preferred method of manufacturing the spring assembly 31comprises the steps of providing a continuous stream of wire 82 to acoiler 12. A continuous stream of plugs 84 is provided to an insertdevice 36 positioned in the coiler 12. The wire 82 is coiled into afirst reduced portion 26. The core 38 is inserted behind the firstreduced portion 26. A coil body 30 is formed from the wire 82, whereinthe body 30 has a diameter 18 sufficiently large to contain the core 38.In the embodiment shown in FIGS. 1 and 6, the core 38 is inserted behindthe first reduced diameter 26. The wire 82 is coiled into a secondreduced diameter 34 behind the core 38. One preferred method includessingulating the cores prior to transferring the cores to the secondposition 50, other methods will be apparent to those of skill in the artfrom the teachings disclosed herein.

[0055] One unified method of manufacturing spring assemblies 31 includesinserting a core 38 at a predetermined point in the coiling process,wherein the predetermined point in the coiling process is after andbefore the first and second reduced coil portions, respectively, areformed. It will be apparent that multiple plugs 38 may be inserted intothe spring 14. The plugs 38 may be separated by empty or filled coiledsections. Since, the arbor 78 cuts the spring 14 into a predeterminedlength, a variety of spring assembly 31 configurations may bemanufactured according to the present invention. A control panel 104having input means 106 and visual output means 108 may be used toprogram, monitor, track and adjust the process. The core installationprocess may be carried out with mechanical switching and cams inconjunction with, or as an alternative to, a computer automated process.

[0056] A sorter 86 is operably positioned to sort the spring assemblies31 into good product and scrap. See FIG. 1-3. The good product passesthrough a stress relief oven 88 placed in line. The stress relief oven88 relieves stresses formed by cold coiling the wire 82. Good productleaving the stress relief oven 88 is accumulated in part/productreceptacle 90. The low, or sub-standard, quality springs and springassemblies are sorted into scrap receptacle 100. A detector above adischarge chute (not shown) detects whether a sub-standard springassembly 31 will be ejected as a rejected part. Detectors are notrequired for most applications.

[0057] A pneumatic switch pack 102 is operably positioned to supply airto run the actuators, move the core through the system and to blow thefinished part off the machine. Part ejection from machine tooling isalso often accomplished via an air blast. Switching is generallycontrolled by the coiling machine computer. Firing sequences andoperation timings are thus precisely controlled.

[0058] Cores may be selected to meet specific applications. For examplethe spring assemblies may be used to dampen vibrations as compared tostandard coils. Neoprene, or malleable rubber (such as used incompressible ear plugs) are suitable for some applications, while rigidcores are more appropriate for other applications. In particularapplications the core 38 is a sound damper. The sound damper may beadapted to dampen electromagnetic energy generally and electrical (RF)specifically; audible sounds, i.e. with the range of human hearing maybe dampened as well. A ferrite core may be used to shift the radiofrequency. Accordingly, the material from which the core is made may beoptimized for specific applications. The cores may also be of bothgeneral and specific materials. Reduction of coil material weight may beachieved by creating a false solid height.

[0059] It will also be apparent from the foregoing that the term “wire”is not limited to metallic material or filaments. Specifically, the wirematerial and the core material may be selected to achieve a desiredinteraction (or lack of interaction) between the two. Tubular wires(coils) maybe filled with a desired gas to achieve a desiredthermodynamic result as a result of the wire-core interaction.

[0060] More generally, the spring assembly 31 comprises a coil 14 havingan interior 24 and a core 38 inserted into the coil interior 24. Thecore 38 sufficiently contacts the coil 14 to be maintained in the coilinterior 24. In one preferred embodiment the core 38 is deformable. Thisallows the core to have an outer diameter 40 at least as large as thecoil interior 24. The core 38 should be sufficiently deformable to beinserted into the coil interior 24. When the core 38 expands from adeformed state to a non-deformed state, the coil 14 forms aninterference fit, for example, in the coil interior 24 with the core 38.More specifically the core outer diameter is preferably at least aslarge as the coil inner diameter. Although not required, the core 38should have sufficient lubricity (that is lubrication, slipperiness, andthe like) to be inserted into the coil interior 24. The coil 14 mayimpart a compressive diametric force to the core 38 to maintain the core38 in the coil interior 24. This is particularly the case when the coreexpands from the deformed state.

[0061] Thus, although there have been described particular embodimentsof the present invention of a new and useful coiling machine and methodof coiling, it is not intended that such references be construed aslimitations upon the scope of this invention except as set forth in thefollowing claims.

The invention claimed is:
 1. A coiling machine comprising: a coileradapted to form a coil having a first diameter and a second diameter,wherein the second diameter is smaller than the first diameter; and aninsert device positioned to insert a core into the coil wherein the corehas a core diameter between the first diameter and the second diameter.2. The coiling machine of claim 1 , wherein the insert device comprisestransfer structure including: a transfer block for transferring the corefrom a first position to a second position adjacent the coil; and atransfer element positioned to transfer the core from the transfer blockto the coil.
 3. The coiling machine of claim 2 , wherein the transferblock is movable.
 4. The coiling machine of claim 3 , wherein thetransfer block is air actuated.
 5. The coiling machine of claim 2 ,wherein the transfer element is a plunger adjacent the second position.6. The coiling machine of claim 5 , wherein the air cylinder has aplunger positioned to be insertable into the coil.
 7. The coilingmachine of claim 2 , further comprising feed structure positioned tofeed the core to the transfer block at the first position.
 8. Thecoiling machine of claim 7 , wherein the transfer block is movablebetween the first position and the second position.
 9. The coilingmachine of claim 8 , wherein the feed structure comprises a conduithaving a first end adjacent the first position.
 10. The coiling machineof claim 9 , wherein the feed structure includes a vibratory feed bowland the conduit includes a second end positioned to receive the corefrom the vibratory feed bowl.
 11. The coiling machine of claim 9 ,wherein the conduit includes a feed tube including the first end and atrack connected to the feed tube.
 12. The coiling machine of claim 11 ,wherein the feed structure comprises a feed mechanism connecting thetrack to the feed tube.
 13. The coiling machine of claim 1 , furthercomprising feed structure positioned to feed the core to the insertdevice.
 14. The coiling machine of claim 13 , wherein the feed structureincluding: a vibratory feed bowl; and a conduit having a first endpositioned to feed the core to the insert device and a second endpositioned to receive the core from the vibratory feed bowl.
 15. Thecoiling machine of claim 14 , wherein the vibratory feed bowl ispositioned higher than the conduit first end.
 16. The coiling machine ofclaim 13 , wherein the feed structure comprises orienting and stagingmeans for staging and orienting the core for delivery to the insertdevice.
 17. The coiling machine of claim 1 , wherein the core is a sounddampener.
 18. A coiling machine comprising: a coiler adapted to form acoil having a first diameter and a plurality of reduced portions oflesser diameter than the first diameter, the plurality of reducedportions including a first reduced portion and a second reduced portionlocated a spaced distance from the first reduced portion; and an insertdevice positioned to insert a core in the coil between the first andsecond reduced portions.
 19. The coiling machine of claim 18 , whereinthe insert device comprises a transfer block movable from a firstposition to a second position to transfer the core from the firstposition to the second position, wherein the second position is adjacentto the coil.
 20. The coiling machine of claim 19 , wherein the insertdevice further comprises a transfer element positioned to insert thecore into the coil from the second position.
 21. The coiling machine ofclaim 20 , wherein the transfer element is a plunger.
 22. The coilingmachine of claim 18 , wherein the insert device comprises a transferelement positioned to insert the core into the coil.
 23. The coilingmachine of claim 18 , further comprising a core source including avibratory bowl connected to the insert device.
 24. A method of reducingvibration comprising the steps of: coiling a wire into a coil via anautomated process, including forming a first reduced portion in thecoil; and inserting a core into the coil via an automated process; andallowing the core to dissipate vibrations.
 25. The method of claim 24 ,comprising the step of securing the core in the coil.
 26. The method ofclaim 24 , wherein the automated process comprises forming a secondreduced portion in the coil after the core is inserted into the coil.27. The method of claim 26 , wherein the core is positioned behind thefirst reduced portion and the second reduced portion is positionedbehind the core, whereby the core is positioned between the first andsecond reduced portions.